Future LBP-2460, WX Technical Instructions

WXTECH

Technical Instructions Printers OEM Info Tools 1

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Canon LBP-2460
Data Products DD524

P 5Si, 5Si MX, 5Si Mopier

H
IBM Network Printer 24
Lexmark Optra N Model 240
QMS 2425-2425 EX
Troy 524

Photo 1

Photo 2a

Photo 2b

Part Number: C3909A
Gram Load: 840 grams
Yield @ 5%: 15,000 pgs
Pages/Min.: 24ppm
Resolution: 600 dpi

Step 1

Locate and remove the cartridge clips on
both sides of the cartridge using your fin­ger. Gently pry up on the clip until it pops
up.

(See Photo 1)

ep 2

St

Using a flat blade screwdriver, pry up on
the other clip and remove it.

(See Photo 2a)

NOTE: I

eak while the

br
these break, replace with aftermarket
part. You may need to use the springs

om the OEM clip

fr

(See Photo 2b)

Needle Nose Pliers

mall Flat Blade Screwdriver

S
#2 Phillips Head Screwdriver
Small Hammer
Soft Lint-Free Cloth/ Damp Cloth
5/32” Drift Punch
Anhydrous Isopropyl Alcohol
800gms 5Si Toner
Nu-Finish (optional)
Damp Cloth

t is very likely that these clips will

eing removed. If

e b

y ar

.

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2 WX Technical Instructions

Notes

Photo 3

Photo 4

Photo 5

Step 3

Just like the HP4 cartridge, the two halves
of the cartridge can now be separated.

(See Photo 3)

Step 4

Set the hopper aside. If you have a waste
hopper fixture, set the waste hopper in the
fixture. If not, place the waste hopper on
the table.

(See Photo 4)

Step 5

The drum axle is a metal rod that goes
through the center of the drum end to
end. On the large gear end of the axle is a
small white plastic retaining ring. Using a
drift punch and a hammer, tap directly on
the shaft (large gear side) and drive it out
the other end. (See Photo 5)

NOTE: Make sure you don’t lose the retain­ing ring. The ring fits into a groove on the
drum shaft to hold the shaft in position.
Repeated removal will wear this ring and
the ring will no longer snap into position.
If the ring does not snap, replace it.

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Instructions for another engine?

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o 6

hot

P

Photo 7

ep 6

St

Remove the drum, blow off excess toner
with compressed air and clean with iso­propyl alcohol. Wrap the drum in a protec­tive paper or cloth and set it aside in a dark,

ted place. (S

ec

ot

pr

ee P

o 6)

hot

NOTE: We were able to use the OEM drum

ter the Oem cycle with no loss in

e af

onc
density, however, you may choose to
recoat or replace the drum after the first
recharge.

Step 7

Remove the primary charge roller from its

lean clips with isopr

clips.

C
and a cotton swab. Inspect the primary
charge roller for damage. Clean the pri-

y charge roller with a mild soap and

mar
water and set it aside.

ee Photo 7)

(S

NOTE: We have had no problems using the
OEM primary charge roller three cycles in
mild weather climates.

opyl alcohol

WX Technical Instructions 3

Photo 8

Photo 9

S

tep 8

Remove the two Phillips head screws hold­ing the wiper blade and remove the blade.
Be careful not to break the plastic position­ing posts.

(See Photo 8)

Step 9

Empty out the waste toner and clean felts
and foam with a vacuum or compressed
air.

(See Photo 9)

NOTE: Be careful not to damage felts,
foam or the mylar recovery blade, as this
can cause leaks. If the felts or foam are
damaged or worn, replace.

Notes

Photo 10

hoto 12

P

Step 10

Apply OPC protector felt to the drum
shutter door. You will need to remove the
cartridge from the fixture.

(See Photo10)

Step 11

Apply padding powder on wiper blade
and reinstall.

NOTE: If you are going to use a new after­market drum, always replace wiper blade.

Step 12

Apply padding powder to the OPC drum
and install. The big helical gear will go on
the right side of the waste hopper. Install
the drum axle only far enough to hold the
drum against the wiper blade. Rotate
drum so the wiper blade wipes the
padding powder off the drum.

(See Photo12)

Step 13

Once again, remove the drum axle and the drum. Reinstall the primary charge roller
then reinstall the drum and drum axle.

NOTE: When reinstalling the drum axle, the axle slides through the drum from the
left side. Make sure you install the axle in the right way. The notched end of the axle
goes on the large gear end.

N

eed help with a particular remanu-

facturing problem?

Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

4 WX Technical Instructions

Notes

Photo 14

Photo 17

Photo 18

Step 14

Install the retaining ring.

(See Photo 14)

Step 15

Set waste hopper aside and cover.

Step 16

If you have a toner hopper fixture, place
toner hopper in fixture or place toner
hopper on the workbench.

Step 17

Remove the two screws holding the end
cap on the gear side of the toner hopper.

(See Photo 17)

Step 18

Before removing the end cap, lift the bias
strip off its positioning post next to the
doctor blade.

(See Photo 18)

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o 19

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P

Photo 20

Step 19

Slide the end cap off. Note the position of
the white gears, then remove the four
largest ones and set them aside.

(See Photo 19)

Step 20

n the c

ur

T
two screws that hold the other end cap
on and remove.

(See Photo 20)

artridge around. Remove the

WX Technical Instructions 5

Photo 21a

Photo 21b

Step 21

Lift out mag roller. Remove the mag roller

tabilizer, mag roller sleeve bearing and

s
mag roller sleeve bushing from the non­gear side of the mag roller and clean.

(See Photo 21a and 21b)

Use compressed air or a vacuum and
remove the extra toner off the mag roller.
Use mag roller cleaner to remove any
residue built up on mag roller.

NOTE: If you are going to have your mag
rollers coated or replaced, you’ll need to
remove the mag roller contact, the gear,
mag roller stabilizer, the bearing and the
bushing from the other side of the mag

oller.

r

To remove the gear off the mag roller, use
a very small flat blade screwdriver to pry
back the prong on the gear. Remove the
non-gear side hub and send in mag roller
to be coated.

The mag roller bearings have a difference
in the inner diameter size and are not
interchangeable. HP also made two dif­ferent mag rollers. The only difference is
in the length of the shaft and the hub.It
is very important to keep the parts
together. The long shaft uses a shorter
hub. When the mag rollers are put
together correctly,they can be used inter­changeably in different cartridges.

Notes

o 22

hot

P

Photo 23

Step 22

Remove the two screws that hold the
doctor blade and lift it out. Clean and set

he doctor blade can wear out

T

.

aside
after a few cycles, check and replace if
necessary.

(See Photo 22)

ep 23

St

Turn the cartridge around to the gear
side once again. Remove the two other
gears. Remember which gear goes
where. These gears turn the toner paddle
bars inside the toner hopper. The bars
will fall into the toner hopper. Remove
these t
t

oner paddle bars from inside the

.

oner hopp

er

(S

ee P

hot

o 23)

N

eed help with a particular remanu-

facturing problem?

Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

6 WX Technical Instructions

Notes

Photo 24

Photo 25

Photo 26

S

tep 24

The bars are the same so don’t worry
about getting them mixed up. Also,

emove the toner paddle bar felt washers.

r
Look at the washers to make sure toner is
not leaking through them. After a few
cycles, these felt washers will wear out
and need to be replaced.

(See Photo 24)

Step 25

Remove toner sensing bar. Make sure you
don’t lose the toner sensor bar seal. Clean
the sensor bar with a cloth and alc

NOTE: Do not bend the sensor bar.

(See Photo 25)

ohol.

Step 26

Remove leftover toner and clean the felts
and foam seals with compressed air or
vacuum. Be careful not to damage any of
the foam, felt strips, or the thin mylar strip
on the bottom lip of the toner hopper. If
these are damaged, the cartridge will
leak.

(See Photo 26)

hoto 27

P

Photo 28a

Step 27

At this point, if you are not going to seal
this cartridge, you can fill it with toner
now through the mag roller opening
then start reassembling cartridge.

(See Photo 27)

If you wish to split and seal the toner hop-

er first, proceed to the next step.

p

Step 28

Place cartridge in splitter fixture. Hold
cartridge in place and slide cutting unit
along the guide t

.

split

hoto 28a)

ee P

(S

o ensur

e a good clean

WX Technical Instructions 7

Photo 28b

Photo 29

Photo 30

S

tep 28 cont.

NOTE: The two halves of the toner hopper
are still held together by two pins.

arefully pull the two halves apart.

C

See Photo 28b)

(

Step 29

Use a razor knife to cut off plastic posts at
the base on the non-plug side of the car­tridge. These are removed so a seal can
be used.

ee Photo 29)

(S

Step 30

Using needle nose pliers,pinch the retain­ing clips of the agitator, and remove the
agitator drive assembly. Remove the
toner agitator felt washer. If toner is leak­ing through opening, replace the washer.

(See Photo 30)

Notes

o 31

hot

P

Photo 32

Step 31

Use isopropyl alcohol and clean surface
of toner hopper where cartridge was

.

split

o 31)

hot

ee P

(S

Step 32

Remove backing from the seal. With the
tail of the seal on the lef

idge (the plug side),

tr

t side of the c

e seal t

adher

toner hopper.

o 32)

hot

ee P

(S

TE:Use your finger to press around

NO

the seal t

o mak

e sur

e of a go

od adhesion.

ar

o the

-

N

eed help with a particular remanu-

facturing problem?

Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

8 WX Technical Instructions

Notes

Photo 33

Photo 34

Photo 35

S

tep 33

Remove fill plug and fill with toner.

See Photo 33)

(

Step 34

Use compressed air or a vacuum and
clean the toner hopper seal channel end

oam on the back of the mag roller sec-

f
tion. Wipe off the back of the mag roller
section.

(See Photo 34)

NOTE: If these foam pads are damaged,
they need to be replaced.

Step 35

These foam strips stop the cartridge from
leaking after it has been split. The foam
strips are applied right across the seal
channel end foam.

(See Photo 35)

hoto 36

P

Photo 37

Step 36

Fold the seal back across the toner hop­per. Now re-join the mag roller section
and the toner hopper section.

(S

ee Photo 36)

NOTE: The posts on the mag roller section
needs to fit back into the holes on the

oner hopper section.

t

Step 37

Using the toner hopper clips, clip the two
sections together.

o 37)

hot

ee P

(S

WX Technical Instructions 9

Photo 38

Photo 39

Photo 40

S

tep 38

Reinstall the toner paddle bar felts and
the bar gears that hold them in. Then

nstall toner sensor bar.

i

See Photo 38)

(

Step 39

Put a little fresh toner on the doctor blade
and reinstall.

(See Photo 39)

Step 40

Place the mag roller bushing, mag roller
bearing,and the mag roller stabilizer back
on the mag roller. Install mag roller back
onto toner hopper.

(See Photo 40)

Notes

o 41

hot

P

Photo 42

Step 41

Reinstall all the gears on the toner hop­per.

(See Photo 41)

ep 42

St

Now install the gear side end cap, align­ing the “flat sided shaft” of the magnet
with its “D”shaped hole and the position­ing pins thr

ough the mag r

holes and then pr

ess do

oller stabiliz

Install t

wn.

Phillips head screws. Align the metal bias

o the plastic pin next to the doctor

ap t

str

osition so tha

o p

t

blade and pr

ess in

contacts the doctor blade.

o 42)

hot

ee P

(S

er

w

t it

o

N

eed help with a particular remanu-

facturing problem?

Call the Technical Resource Center from
8am - 5pm PST: 800 394.9900

10 WX Technical Instructions

Notes

Photo 43

Photo 45

S

tep 43

Do the same with the end cap on the
other side and apply pull tab to seal.

(See Photo 43)

Step 44

Align the toner hopper and waste hopper
assemblies together.

Step 45

Snap the OEM or aftermarket cartridge
clip back into position.

(See Photo 45)

Future Graphics (FG) is a distributor of compatible replacement parts and products for imagining equipment. None of FG's

o

pr

duc

ts ar

e genuine OEM r

eplac

emen

ts and no affilia

t par

onsorship is to be implied between FG and any OEM.

tion or sp

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